Apparatus for casting solder on a moving strip

ABSTRACT

An apparatus for casting molten metal onto a moving strip of material includes a stationary die having upstream and downstream portions with a casting portion, past which the strip of material is capable of being moved. The casting portion has a casting channel extending from the upstream portion through the downstream portion for facing the moving strip to contain and shape the molten metal into a profile against the moving strip. A heating arrangement heats the upstream portion of the stationary die to prevent the molten metal from solidifying within the casting channel at the upstream portion, thereby allowing the molten metal to fill the casting channel. The casting channel at the downstream portion allows the molten metal to cool while passing therethrough to solidify sufficiently to retain the shape of the casting channel when exiting the stationary die.

RELATED APPLICATION

[0001] This application is a continuation of U.S. application Ser. No.09/845,762, filed May 1, 2001. The entire teachings of the aboveapplication are incorporated herein by reference.

BACKGROUND

[0002] Some electrical components are formed from a copper ribbon havinga centrally positioned narrower strip of solder extending longitudinallythereon. The common method currently used for manufacturing such aproduct is to place a solder ribbon on a copper ribbon that is widerthan the solder ribbon and melt the solder ribbon onto the copperribbon. The molten solder is then allowed to solidify and bond thereon.When the solder ribbon melts, the molten solder tends to flowuncontrollably so that the overall dimensions and surface finish of theresulting solder layer are inconsistent. In order to provide a copperribbon product that has a dimensionally consistent layer of solderthereon, the layer of solder must then be machined to the desireddimensions. A drawback of this method is that it wastes material, it isinefficient, and fairly expensive.

SUMMARY

[0003] The present invention is directed to an apparatus and method forforming a metallic profile on a strip of material in an efficient andcost effective manner. The present invention is directed to an apparatusfor casting molten metal onto a moving strip of material including astationary die having upstream and downstream portions with a castingportion, past which the strip of material is capable of being moved. Thecasting portion has a casting channel extending from the upstreamportion through the downstream portion for facing the moving strip forcontaining and shaping the molten metal into a profile against themoving strip. A heating arrangement heats the upstream portion of thestationary die to prevent the molten metal from solidifying within thecasting channel at the upstream portion, thereby allowing the moltenmetal to fill the casting channel. The casting channel at the downstreamportion allows the molten metal to cool while passing therethrough tosolidify sufficiently to retain the shape of the casting channel whenexiting the stationary die.

[0004] In preferred embodiments, the moving strip is a metallic stripand the molten metal is molten solder. A preheating station preheats themoving strip prior to casting the molten metal thereon. The heatingarrangement on the upstream portion of the stationary die includes atleast one heating device. A cooling system cools the downstream portionof the stationary die and may be a recirculating fluid cooling system.The casting portion of the stationary die is adapted to abut the movingstrip such that the casting channel of the stationary die and the movingstrip define the profile of the cast metal therebetween. A guide channelis formed in the casting portion of the stationary die for guiding themoving strip therethrough in relation to the casting channel. The movingstrip is held against the casting portion by a support portion of thestationary die. A reservoir for containing a supply of molten metal isformed in the stationary die in communication with the casting channel.The reservoir and the casting channel are connected by a taperingtransition region. A delivery conduit delivers molten metal to thereservoir and the stationary die. A heated chamber stores the moltenmetal and supplies the delivery conduit with the molten metal which ispumped through the delivery conduit by a pumping device.

[0005] The present invention is also directed to a stationary die forcasting molten metal onto a moving strip of material including areservoir for containing molten metal. The stationary die also includesa casting channel having casting surfaces for containing and shaping themolten metal into a profile against the moving strip. A taperingtransition region connects the reservoir to the casting channel, whereinthe reservoir, the transition region and the casting channel arelongitudinally aligned and configured to face the moving strip.

[0006] The present invention is further directed to a method of castingmolten metal onto a moving strip of material including moving the stripof material past a stationary die having upstream and downstreamportions. A casting channel faces the moving strip and extends from theupstream portion through the downstream portion. The molten metal iscontained and shaped into a profile against the moving strip with thecasting channel. The upstream portion of the stationary die is heated toprevent the molten metal from solidifying within the casting channel atthe upstream portion, thereby allowing the molten metal to fill thecasting channel. The molten metal is allowed to cool while passingthrough the casting channel at the downstream portion to solidifysufficiently to retain the shape of the casting channel when exiting thestationary die.

[0007] The present invention is able to manufacture a ribbon of materialhaving a profiled layer of metal thereon in a manner where the profiledoes not have to be later machined in an additional process. This savesmaterial, time and labor and it therefore costs less to produce such aproduct in a manner according to the present invention than with thecommon prior method.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The foregoing and other objects, features and advantages of theinvention will be apparent from the following more particulardescription of preferred embodiments of the invention, as illustrated inthe accompanying drawings in which like reference characters refer tothe same parts throughout the different views. The drawings are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the invention.

[0009]FIG. 1 is a schematic view of an embodiment of the presentinvention casting apparatus.

[0010]FIG. 2 is a side sectional view of a casting die that is castingmolten metal on a moving strip.

[0011]FIG. 3 is a sectional view of the casting die of FIG. 2 takenalong lines 3-3.

[0012]FIG. 4 is a sectional view of the casting die of FIG. 2 takenalong lines 4-4.

[0013]FIG. 5 is a perspective view of a metallic ribbon having a profileof cast metal formed thereon in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0014] Referring to FIG. 1, casting apparatus 10 is employed for castinga dimensionally consistent profile 62 (FIG. 5) of metal such as solderonto a moving metallic strip or ribbon 22, for example, formed fromcopper. Casting apparatus 10 generally includes an unwind station 12 forunwinding the metallic ribbon 22 from a roll 20, a preheating station 14for preheating the metallic ribbon 22, a casting station 16 for castingmolten solder 46 onto the metallic ribbon 22, and a windup station 18for winding the resulting bimetal laminate product 63 into a roll 36.

[0015] In use, metallic ribbon 22 unwound from roll 20 at unwind station12, passes through and is preheated within the interior 26 of a heatingchamber 24 by a heater 28 at preheating station 14. The metallic ribbon22 then passes through a stationary casting die 38 at casting station16. Molten solder 46 is pumped by a pump 48 from a heated pot or chamber44 through inlet pipe 50 to the casting die 38. The interior of castingdie 38 is shaped to guide the metallic ribbon 22 therethrough as well asto mold the molten solder 46 onto the metallic ribbon 22. The castingdie 38 has an upstream portion 37 a that is heated by heaters 40 tolengthen the time that the molten solder 46 is in a liquid state so thatthe solder 46 does not solidify too quickly. The molten solder 46 isshaped or formed by casting die 38 onto the metallic ribbon 22 whilemoving through casting die 38. The molten solder 46 begins solidifyingwhile still within the casting die 38. Shortly after exiting the castingdie 38, the once molten solder 46 has been transformed into adimensionally consistent profile 62 of hardened or solidified solder 46a (FIG. 5) that is adhered or bonded to the metallic ribbon 22, therebyresulting in a bimetal laminate 63. Casting die 38 has a downstreamportion 37 b which is cooled by coolers 42 to speed up thesolidification process of the molten solder 46 while passing through thedownstream portion 37 b of casting die 38. The bimetal laminate 63 isthen rolled up into a roll 36 at windup station 18.

[0016] A more detailed description of casting apparatus 10 now follows.Unwind station 12 typically includes an axle 20 a upon which roll 20 isplaced, thereby allowing roll 20 to spin or rotate while metallic ribbon22 is pulled therefrom. Axle 20 a is commonly a rod that is positionedhorizontally as shown. Optionally, axle 20 a can be extended verticallyfrom a flat surface so that roll 20 is unwound from a horizontalposition. The rod is typically stationary but can be fitted withbearings for rotation. Optionally, a brake 21 can be employed to controlthe speed at which roll 20 spins. Additionally, the rotation of roll 20can alternatively be controlled by driving axle 20 a with a motor.

[0017] Windup station 18 includes a power driven axle 36 a which windsthe finished bimetal laminate 63 into a roll 36. In the embodiment shownin FIG. 1, windup station 18 also pulls the metallic ribbon 22 from roll20 and through casting die 38. An idler roll 34 is positioned betweencasting die 38 and windup station 18 for guiding the bimetal laminate63. Alternatively, a pair of opposed drive rolls may be positionedupstream of casting die 38 for pulling metallic ribbon 22 from roll 20in which case windup station 18 only pulls metallic ribbon 22 throughcasting die 38 before winding up the bimetal laminate 63.

[0018] Preheating station 14 includes a narrow elongate heating chamber24 having narrow horizontal slot like openings 24 a at the upstream 23 aand downstream 23 b ends for allowing the metallic ribbon 22 to enterand exit heating chamber 24. Idler rollers 30 and 32 positioned near theupstream 23 a and downstream 23 b ends, respectively, help guide themetallic ribbon 22 into and from heating chamber 24. Heating chamber 24is preferably made of metal such as sheet steel in order to withstandheat, but may be made of other suitable materials such as ceramics ormasonry. In the embodiment shown in FIG. 1, heating chamber 24 isgenerally cylindrical in shape with a circular cross section. In thisembodiment, heater 28 is typically a hot air blower/heater which blowshot air into the interior of heating chamber 24, thereby heating theinterior thereof, and is capable of heating the metallic ribbon 22moving within heating chamber 24 to about 150° F. The narrow slot likeopenings 24 a minimize the amount of heat contained within heatingchamber 24 that escapes. Preheating metallic ribbon 22 helps the moltensolder 46 adhere better to metallic ribbon 22. Some contaminants on thesurfaces of metallic ribbon 22 may be removed by the preheating process.Although heating chamber 24 is preferably cylindrical in shape,alternatively, heating chamber 24 can have any suitable cross sectionsuch as a rectangular or polygonal cross section, or a cross sectionformed by a combination of curves, or curves and planar sections. Thelength of heating chamber 24 may be varied depending upon the speed atwhich metallic ribbon 22 moves. For example, in one embodiment, heatingchamber 24 is three to five feet long. Although a hot air blower/heateris preferred for preheating metallic ribbon 22, alternatively,electrical heating elements or flames can be positioned within heatingchamber 24 along its longitudinal length.

[0019] Pot or chamber 44 melts and keeps the solder 46 in a liquid stateat a temperature of about 600° F. to 650° F. for a solder composition ofabout 25% tin (Sn), 62% lead (Pb), 10% bismuth (Bi) and 3% silver (Ag).It is understood that the temperature of molten solder 46 within pot 44will vary depending upon the composition of the solder employed sincedifferent solder compositions have different melting points. The inletpipe 50 connected to casting die 38 is heated by a heater 52 so that themolten solder 46 pumped therethrough by pump 48 does not solidify withininlet pipe 50. Heater 52 is typically a heating coil that is wrappedaround inlet pipe 50 as shown. Pump 48 preferably pressurizes castingdie 38 with molten solder 46. A return pipe 54 can be optionally coupledbetween casting die 38 and pot 44 to allow excess molten solder 46 toreturn to pot 44 in order to help control the pressure of the moltensolder 44 within casting die 38 to a constant level. The pressure of themolten solder 46 can be further controlled by a pressure control valvecoupled to return pipe 54. Return pipe 54 is also heated by a heater 52.

[0020] Referring to FIGS. 2-4, casting die 38 typically includes acasting portion 38 a and a supporting portion 38 b which are clampedtogether by a series of bolts 76 (FIG. 2). The support portion 38 b hasa flat surface 73 which mates with the flat surface 75 of castingportion 38 a. Springs such as Belville spring washers 76 a can beoptionally employed to allow portions 38 a/38 b to move apart slightlyto accommodate thermal expansion of metallic ribbon 22 within castingdie 38. The casting portion 38 a includes a small cavity therein forminga solder reservoir 68. The solder reservoir 68 has an inlet opening 64to which the inlet pipe 50 from pot 44 is coupled. If a return pipe 54to pot 44 is employed, an outlet opening 66 is formed which is coupledto return pipe 54. In the embodiment shown, casting portion 38 a alsohas a centrally positioned guide channel 74 formed within the flatsurface 75 (FIGS. 3 and 4) longitudinally along the length of castingportion 38 a for guiding metallic the ribbon 22 therethrough. A castingchannel 72 is centrally formed within guide channel 74 downstream fromsolder reservoir 68 and has casting surfaces 72 a for casting the moltensolder 46 onto the metallic strip 22 in the desired profile 62 withconsistent dimensions. The solder reservoir 68 and the casting channel72 are connected to each other by a tapering transition region 70 whichcurves from the deeper solder reservoir 68 to join with the shallowercasting channel 72. The transition region 70 can be angled rather thancurved. As can be seen in FIG. 2, the solder reservoir 68, thetransition region 70 and the casting channel 72 are horizontally orlongitudinally positioned in line with each other in the direction ofsolder flow and face the metallic strip 22. Although FIG. 3 depicts thesolder reservoir 68, the transition region 70 and the casting channel 72all having the same width, alternatively, in some embodiments, solderreservoir 68 and transition region 70 are narrower than casting channel72. The guide channel 74 extends through the flat surface 75 of castingportion 38 a and is therefore open on that side. Consequently, theregion of the flat surface 73 of support portion 38 b that faces guidechannel 74 forms a support structure or surface 73 a for enclosing guidechannel 74 to support and trap the metallic ribbon 22 to abut againstcasting portion 38 a within guide channel 74. Alternatively, the guidechannel 74 can be formed in the support portion 38 b. In addition, halfof the guide channel 74 can be formed in the casting portion 38 a andhalf in the support portion 38 b.

[0021] Both casting and support portions 38 a/38 b of casting die 38have a series of holes 40 a therethrough at the upstream portion 37 afor receiving electric heaters 40 therein (FIGS. 1 and 2).Alternatively, heating devices may be positioned externally aboutcasting die 38. The heaters 40 heat the casting die 38 to a temperaturesufficient to keep the molten solder 46 in a liquid form long enough toflow within casting channel 72 to fill and be formed by casting channel72. The heaters 40 are typically all set at the same temperature but,alternatively, the downstream heaters 40 may be set at lowertemperatures than the upstream heaters 40 to gradually lower thetemperature of the molten solder 46 as the molten solder 46 continues totravel through the casting channel 72. The downstream portion 37 b ofcasting and support portions 38 a/38 b are cooled by coolers 42 (FIG. 1)for more rapidly solidifying the molten solder 46 moving within thedownstream portion 37 b of casting channel 72. Coolers 42 are typicallywater cooled blocks of copper that are placed at the downstream portion37 b of casting and support portions 38 a/38 b. Water cooled by achiller 60 is circulated through passages in the copper blocks via waterlines 56 and 58. Alternatively, passages for the chilled water can beformed directly within the casting and support portions 38 a/38 b. Also,cooling devices can be mounted externally to casting die 38.

[0022] Casting die 38 is preferably formed of hardened steel and may beplated, such as with chrome, for example, or other suitable materials towhich solder does not readily adhere. The length of casting die istypically 7 to 12 inches long with 7-9 inches being the more commonlength. Longer casting die lengths are also possible. In an embodimentfor casting a rectangular profile 62 of hardened solder 46 a that is0.620 inch wide by 0.014 inch high, on a metallic ribbon 22 that is tincoated and 0.031 inches thick by 1.516 inches wide such as that seen inFIG. 5, solder reservoir is about {fraction (1/4)} inch deep, {fraction(1/2)} inch wide and about 3 inches long. The casting channel 72 is0.015 inch deep by 0.622 inch wide. Transition region 70 is about 1 inchlong and is about 0.050 inches deeper than casting channel 72 at theupstream end before gradually curving to join with casting channel 72.Casting die 38 is capable of molding molten solder 46 onto metallicribbon 22 at speeds as slow as 5 feet per minute without significantleakage of molten solder from casting channel 72.

[0023] Referring to FIG. 2, when casting molten solder 46 onto themetallic ribbon 22, the metallic ribbon 22 moves through casting die 38while being guided by guide channel 74. Portions of the heated castingand support portions 38 a/38 b of casting die 38 which contact metallicribbon 22 further heat the metallic ribbon 22 by conduction. The moltensolder 46 occupying solder reservoir 68 is in contact with the metallicribbon 22. Guide channel 74 has sealing surfaces 74 a surrounding solderreservoir 68 on the upstream (FIG. 2) and lateral sides as well as onthe lateral sides of transition region 70 and casting channel 72 (FIGS.3 and 4) which seal against the surface of metallic ribbon 22 to preventleakage therebetween. The support portion 38 b presses the metallicribbon 22 to abut against the sealing surfaces 74 a of the castingportion 38 a with enough pressure to provide such sealing. Consequently,the molten solder 46 is limited to flowing downstream into the castingchannel 72. As the metallic ribbon 22 moves past solder reservoir 68,the molten solder 46 contacting metallic ribbon 22 bonds with and ispulled downstream by the moving metallic ribbon 22 in the direction ofarrows “A” into transition region 70 (FIG. 2). The transition region 70tapers into the casting channel 72 so that the transition from thedeeper solder reservoir 68 to the shallower casting channel 72 isgradual (FIGS. 2 and 3). Therefore, the molten solder 46 moving in thedirection of arrows “A” is able to flow from the solder reservoir 68into the casting channel 72 more easily and quickly. Downstream flow ofthe molten solder 46 within casting channel 72 is limited in part bysolder 46 solidifying downstream within casting channel 72. Solderreservoir 68 is provided with molten solder 46 at a sufficient rate toreplenish the molten solder 46 that is carried away by the movingmetallic ribbon 22 so that casting channel 72 can be continuouslysupplied with enough solder 46 to be completely filled with moltensolder 46. Heating the upstream portion 37 a of casting die 38 keeps themolten solder 46 in a liquid form when the solder 46 enters the castingchannel 72 which allows the solder 46 to flow outwardly to contact thecasting surfaces 72 a and assume the shape defined by the castingsurfaces 72 a of casting channel 72 (FIG. 4). The moving molten solder46 is contained within the volume surrounded by the casting surfaces 72a of casting channel 72 and the metallic ribbon 22. The sealing surfaces74 a of guide channel 74 seal against the surface of the moving metallicribbon 22 on opposite lateral sides of casting channel 72 so that solder46 does not leak from casting channel 72 while still molten. As aresult, the solder 46 is held in the shape of the casting channel 72while traveling through casting die 38 from the molten stage and throughthe stage in which the solder 46 is cooled by coolers 42 and begins tosolidify. The lateral guide surfaces 74 b of guide channel 74 (FIGS. 3and 4) keep the metallic ribbon 22 positioned properly relative tocasting channel 72 so that the molten solder 46 is consistently appliedto metallic ribbon 22 at the desired location.

[0024] The coolers 42 cool the downstream portion 37 b of casting die 38to a temperature sufficient to at least begin to harden the moltensolder 46 moving within casting channel 72 (FIG. 2). Depending upon thetemperature of the downstream portion 37 b of casting die 38 and thespeed of metallic ribbon 22 therethrough, the solder 46 may leave thecasting die 38 while either in a plastic state or in a hardened state.While in the plastic state, the solder 46 is rigid enough to retain theshape of casting channel 72 before completely solidifying shortlythereafter. Moving the solidifying solder 46 through casting channel 72past the casting surfaces 72 a may help smooth the solder 46 so that thefinished profile 62 has a smooth surface finish which would not beprovided if the solder 46 was merely melted onto metallic ribbon 22without casting die 38. As the molten solder 46 begins to solidify, thesolder 46 contracts slightly so that friction between the solidifyingsolder 46 and the casting surfaces 72 a is minimized. In cases where thesolder 46 becomes completely hardened within casting die 38, this allowsthe metallic ribbon 22 and hardened solder 46 to pass through thecasting die 38 without damaging the surface of the profile 62. Thedimensions of the finished cooled profile 62, such as height and width(FIG. 5), is typically consistently about 0.001 to 0.002 inches lessthan the dimensions of the casting channel 72 with a surface variationof ±0.0002 inches after shrinking. Consequently, the finished profile 62can be made with dimensional consistency. Since the metallic ribbon 22is heated to some degree when the molten solder 46 is applied, a strongbond is obtained therebetween. When the solder 46 and the metallicribbon 22 cool, both the solder 46 and the metallic ribbon 22 undergosome shrinking or contracting simultaneously which allows a relativelystrong bond to be maintained therebetween. If the metallic ribbon 22 wasnot heated, shrinkage of the solder 46 relative to the metallic ribbon22 would likely weaken the bond therebetween.

[0025] While this invention has been particularly shown and describedwith references to preferred embodiments thereof, it will be understoodby those skilled in the art that various changes in form and details maybe made therein without departing from the scope of the inventionencompassed by the appended claims.

[0026] For example, a flux station and/or cleaning station can beincluded to treat the metallic ribbon 22 before the casting station 16.Such treating can also include roughening the surface of the metallicribbon 22 for increased adherence of the solder 46 to the metallicribbon 22. In addition, although metallic ribbon 22 is often a tincoated copper ribbon, metallic ribbon 22 can be uncoated copper, as wellas other suitable coated or uncoated metals such as bronze, brass,steel, nickel, etc. Profile 62 can also be cast upon non-metallic heatresistant ribbons or strips by the present invention apparatus. Thepresent invention may be also employed to cast polymers on a movingstrip. Although casting apparatus 10 is shown to cast profile 62 on topof metallic ribbon 22, alternatively, casting apparatus 10 can beconfigured to cast profile 62 onto a ribbon 22 at other suitableorientations such as upside down from that shown. It is understood thatthe positioning of profile 62 on ribbon 22 and the profile configurationcan be varied to any desirable position and configuration. For example,profile 62 can be positioned closer to one edge of ribbon 22 and canhave curved or angled surfaces. Furthermore, the axle 20 a of unwindstation 12 can be replaced with rollers positioned under roll 20 forsupporting and allowing roll 20 to spin while unwinding. Also, althoughthe downstream end of casting die is shown to be cooled by chilledwater, alternatively, an air cooled system can be employed such as withcooling fins and/or forced air. A radiator may be employed with thecooling system.

[0027] Preheating station 14 may be omitted in some applications. Insuch cases, the casting die 38 can be employed to heat the metallicribbon 22 by conduction. The casting die 38 can have an extended heatedsection. Although the stationary casting die 38 is shown to have castingand support portions 38 a/38 b which are each half of casting die 38,the stationary casting die 38 can be formed from portions that areconfigured differently from that shown and can include additionalcomponents. Although a guide channel 74 has been shown for guidingmetallic ribbon 22, alternatively, rollers or intermittent tabs can beemployed for guiding metallic ribbon 22. Also, rollers can be employedfor supporting metallic ribbon 22 against casting portion 38 a. It isunderstood that particular parameters of the components of castingapparatus 10 vary depending upon the application in hand. Typicalvariables include the size and shape of the ribbon 22 and profile 62,the solder composition, speed of ribbon 22, etc. In some embodiments,the solder reservoir 68 and/or transition region 70 of casting die 38can be omitted. The solder reservoir 68 can also be positioned abovecasting channel 72.

What is claimed is:
 1. An apparatus for casting molten metal onto amoving strip of material comprising a stationary die having upstream anddownstream portions with a casting portion, past which the strip ofmaterial is capable of being moved, the casting portion having a castingchannel for filling with the molten metal extending from the upstreamportion through the downstream portion and for facing the moving stripto contain and shape the molten metal into a profile against the movingstrip, the casting channel at the downstream portion allowing the moltenmetal to cool while passing therethrough to solidify sufficiently toretain the shape of the casting channel when exiting the stationary die,the stationary die having only a stationary support for supporting themoving strip against the casting channel.
 2. The apparatus of claim 1 inwhich the apparatus is configured for casting molten solder onto amoving metallic strip.
 3. The apparatus of claim 1 further comprising acooling system for cooling the downstream portion of the stationary die.4. The apparatus of claim 3 further comprising a heating arrangement forheating the upstream portion of the stationary die to prevent the moltenmetal from solidifying within the casting channel at said upstreamportion.
 5. The apparatus of claim 1 in which the casting portion of thestationary die is adapted to abut the moving strip and form sealingsurfaces such that the casting channel of the stationary die and themoving strip define the profile of the cast metal therebetween.
 6. Theapparatus of claim 5 in which a guide channel is formed in the castingportion of the stationary die for guiding the moving strip therethrough,the moving strip being held against the casting portion by a supportportion of the stationary die.
 7. The apparatus of claim 1 in which areservoir for containing a supply of molten metal is formed in thestationary die in communication with the casting channel.
 8. Theapparatus of claim 7 in which the reservoir and casting channel areconnected by a tapering transition region.
 9. The apparatus of claim 8in which the transition region and the casting channel are longitudinglyaligned and configured to face the moving strip.
 10. An apparatus forcasting and bonding molten solder onto a moving metallic stripcomprising a stationary die having upstream and downstream portions witha casting portion, past which the metallic strip is capable of beingmoved, the casting portion having a casting channel for filling with themolten solder extending from the upstream portion through the downstreamportion and for facing the moving metallic strip to contour and shapethe molten solder into a profile against the moving metallic strip, thecasting channel at the downstream portion allowing the solder to coolwhile passing therethrough to solidify sufficiently to retain the shapeof the casting channel when exiting the stationary die, the stationarydie having guide surfaces for guiding the moving metallic strip inrelation to the casting channel and also having only a stationarysupport for supporting the moving strip against the casting channel. 11.A method of forming an apparatus for casting molten metal onto a movingstrip of material comprising: providing a stationary die having upstreamand downstream portions with a casting portion, past which the strip ofmaterial is capable of being moved, the casting portion having a castingchannel for filling with the molten metal extending from the upstreamportion through the downstream portion and for facing the moving stripto contain and shape the molten metal into a profile against the movingstrip, the casting channel at the downstream portion allowing the moltenmetal to cool while passing therethrough to solidify sufficiently toretain the shape of the casting channel when exiting the stationary die;and providing the stationary die with only a stationary support forsupporting the moving strip against the casting channel.
 12. The methodof claim 11 in which the moving strip is a metallic strip and the moltenmetal is molten solder, the method further comprising providing acooling system for cooling the downstream portion of the stationary die.13. The method of claim 12 further comprising providing a heatingarrangement for heating the upstream portion of the stationary die toprevent the molten metal from solidifying within the casting channel atsaid upstream portion.
 14. The method of claim 11 further comprisingadapting the casting portion of the stationary die to abut the movingstrip and form sealing surfaces such that the casting channel of thestationary die and the moving strip define the profile of the cast metaltherebetween.
 15. The method of claim 14 further comprising forming aguide channel in the casting portion of the stationary die for guidingthe moving strip therethrough, the moving strip being held against thecasting portion by a support portion of the stationary die.
 16. Themethod of claim 11 further comprising forming a reservoir for containinga supply of molten metal in the stationary die in communication with thecasting channel.
 17. The method of claim 16 further comprisingconnecting the reservoir and casting channel with a tapering transitionregion, the transition region and the casting channel beinglongitudinally aligned and configured to face the moving strip.
 18. Amethod of casting molten metal onto a moving strip of materialcomprising: moving the strip of material past a stationary die havingupstream and downstream portions, a casting channel facing the movingstrip extending from the upstream portion through the downstreamportion; filling the casting channel with the molten metal; containingand shaping the molten metal into a profile against the moving stripwith the casting channel, the stationary die having only a stationarysupport for supporting the moving strip against the casting channel; andallowing the molten metal to cool while passing through the castingchannel at the downstream portion to solidify sufficiently to retain theshape of the casting channel when exiting the stationary die.
 19. Themethod of claim 18 in which the moving strip is a metallic strip and themolten metal is molten solder, the method further comprising cooling thedownstream portion of the stationary die with a cooling system.
 20. Themethod of claim 18 further comprising heating the upstream portion ofthe stationary die with a heating arrangement to prevent the moltenmetal from solidifying within the casting channel at said upstreamportion.
 21. The method of claim 18 further comprising abutting thecasting portion of the stationary die against the moving strip to formsealing surfaces such that the casting channel of the stationary die andthe moving strip define the profile of the cast metal therebetween. 22.The method of claim 21 further comprising guiding the moving stripthrough the stationary die with a guide channel formed in the castingportion of the stationary die, the moving strip being held against thecasting portion by a support portion of the stationary die.
 23. Themethod of claim 18 further comprising containing a supply of moltenmetal in a reservoir in the stationary die, the reservoir being incommunication with the casting channel.
 24. The method of claim 23further comprising connecting the reservoir and casting channel with atapering transition region, the transition region and the castingchannel being longitudingly aligned and configured to face the movingstrip.
 25. The method of claim 24 further comprising delivering themolten metal to the reservoir in the stationary die with a deliveryconduit.
 26. The method of claim 25 further comprising storing themolten metal in a heated chamber and supplying the delivery conduit withthe molten metal.
 27. The method of claim 26 further comprising pumpingthe molten metal through the delivery conduit with a pumping device. 28.The method of claim 18 further comprising preheating the moving stripprior to casting the molten metal thereon with a preheating station.